Wave roll die assembly

ABSTRACT

A wave rolling assembly and a process for manufacturing a component for a vehicle using the wave rolling assembly is provided. The process includes conveying a metal coil through a first leveler to present a metal sheet, and conveying the metal sheet through a looping pit. The metal sheet travels from the looping pit to the wave rolling assembly for forming a plurality of waves along the side edges of the metal sheet. The wave rolling assembly stretches the metal sheet. The wave rolling assembly can include a die assembly or a roll forming apparatus. The metal sheet is then conveyed through a second leveler to flatten the metal sheet. The metal sheet is cut into blanks and formed into the finished component in a blanking press and die assembly. Less scrap is generated due to the reduced thickness along the edges and overall increased width of the blanks.

CROSS-REFERENCE TO RELATED APPLICATIONS

This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63/119,939, filed Dec. 1, 2020, titled “Wave Roll Die Assembly,” the entire disclosures of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention relates to a wave rolling assembly for forming metal components, such as vehicle components, a system including the wave rolling assembly, and a method for forming the components using the wave rolling assembly.

2. Related Art

Components for vehicles, such as body panels, roofs, and hoods, are oftentimes formed by pressing, stamping, or otherwise shaping a metal blank in a die. The shaped blank is also cut or trimmed to a desired shape. The blank itself can be initially formed from a coil of metal, such as steel or aluminum. Typically, the coil passes through a leveler wherein it is flattened into a thin sheet. The sheet of metal then passes through a looping pit before being shaped in the die and cut to achieve the desired shape. During the cutting step, excess material (scrap) surrounding the finished component is removed. Manufacturers of the vehicle components try to limit the amount of scrap generated in order to reduce costs. One method used to reduce scrap during a trimming process includes vertically cutting waves into opposite ends of the metal blanks (pitch direction). However, additional methods for reducing scrap and thus reducing costs are desired.

SUMMARY

One aspect of the disclosure provides a system for manufacturing a metal component, for example a component for a vehicle. The system includes a wave forming assembly for forming a plurality of waves in a metal sheet. The wave forming assembly includes a plurality of wave roll inserts or rollers spaced from one another for applying pressure to the metal sheet and forming the waves in the metal sheet. The system further includes a leveler for flattening the waves formed by the wave forming assembly. The system also includes a press and die assembly for receiving the metal sheet after the leveler flattens the waves and forming the metal sheet.

Another aspect of the disclosure provides a wave rolling assembly. The wave rolling assembly includes a lower lock bead subplate and a pair of cassettes for receiving a metal sheet therebetween. The pair of cassettes are movable vertically for pressing and forming waves in the metal sheet. The pair of cassettes are also removable and replaceable. Each cassette includes a locking bead forming pad movable vertically and independent from the remainder of the cassette for pressing the metal sheet into the lower lock bead subplate and forming a first wave in the metal sheet. Each cassette also includes an upper wave roll insert adjacent the locking bead forming pad and a lower wave roll insert adjacent the lower lock bead subplate for forming second and third waves therebetween.

Another aspect of the disclosure provides a method of manufacturing a component. The method comprises the steps of: forming a plurality of waves in a metal sheet, flattening the waves formed in the metal sheet, and forming the metal sheet in a pressure and die assembly after flattening the waves.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to limit the scope of the present disclosure. The inventive concepts associated with the present disclosure will be more readily understood by reference to the following description in combination with the accompanying drawings wherein:

FIG. 1 illustrates a system for manufacturing vehicle components using a wave rolling assembly and a second leveler according to an example embodiment;

FIG. 2 illustrates waves in a metal sheet formed by the wave rolling assembly according to an example embodiment;

FIG. 3 is a side cross-sectional view of the waves formed in the metal sheet according to an example embodiment;

FIGS. 4-6 illustrate die assemblies which can be used as the wave rolling assembly according to example embodiments;

FIG. 7 illustrates a roll forming apparatus which can be used as the wave rolling assembly according to an example embodiment; and

FIGS. 8-11 are examples of components formed by a process which includes the wave rolling assembly.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

One aspect of the invention provides a wave rolling assembly 10 used in a process for forming metal components 12, such as vehicle components. Example vehicle components include body panels, doors, roofs, and hoods. However, other types of vehicle components could be formed. The components 12 are typically formed from an aluminum-based or iron-based material, for example an aluminum alloy or steel blank.

An example of a production line including the wave rolling assembly 10 is shown in FIG. 1 . The production line begins with a coil stand 14 including a metal coil 16 wound around a spindle 18. The metal coil 16 is formed of the aluminum-based or iron-based material, which is used to form the component 12.

During the process of manufacturing the component 12, the spindle 18 turns to continuously provide the coil 16 to a first leveler 20. The first leveler 20 includes a plurality of rollers 22, 24 which apply pressure to the coil 16 and progressively flatten the coil 16 and form the coil 16 into a metal sheet 26. The first leveler 20 removes the curl from the coil 16, but does not reduce the thickness of the coil 16. More specifically, the first leveler 20 includes a top row of the rollers 22 and a bottom row of the rollers 24, and the coil 16 travels between the top and bottom rows of rollers 22, 24. The sheet 26 exits the rollers 22, 24 and travels continuously to a looping pit 28. The looping pit 28 is an area of space capable of containing a portion of the sheet 26.

In comparative processes used to form vehicle components 12, the metal sheet 26 travels directly from the looping pit 28 to a press and die assembly 30, where the metal sheet 26 is formed to the desired shape, depending on the intended vehicle application. However, according to embodiments of the present invention, the metal sheet 26 travels from the looping pit 28 to the wave rolling assembly 10 and a second leveler 32, before the press and die assembly 30. The wave rolling assembly 10 and the second leveler 32 pre-draw or stretch out the material of the metal sheet 26 in a width direction, which is traverse to the direction of travel of the metal sheet 26. The pre-drawing and stretching ultimately reduces the amount of scrap produced in the production process, and thus reduces production costs.

More specifically, immediately after the looping pit 28, the metal sheet 26 travels through the wave rolling assembly 10 which forms a plurality of waves 34, 36, 38 in the metal sheet 26. According to an example embodiment, the wave rolling assembly 10 first forms a first wave 34, referred to a lock step, along each outer edge of the metal sheet 26. After the first wave 34 is formed, the wave rolling assembly 10 forms a second wave 36 and a third wave 38 along each outer edge of the metal sheet 26, inward of the first wave 34. The first wave 34 (lock step) holds the metal sheet 26 in place against manufacturing equipment during subsequent forming steps, for example when additional waves 36, 38 are formed and leveled. FIGS. 2 and 3 illustrate an example of the first wave 34 (lock step), second wave 36, and third wave 38 formed at each edge of the metal sheet 26 according to the example embodiment. According to this embodiment, the second and third waves 36, 38 present a height of 10 mm. The waves 34, 36, 38 focus the amount and location of strain created in the metal sheet 26, so that the desired amount and location of stretching and thinning of the metal sheet 26 can be achieved. In addition, less force is required to stretch and thin the metal sheet 26 when the waves 34, 36, 38 are formed in the metal sheet 26, compared to a flat sheet.

Various different devices can be used as the wave rolling assembly 10 to form the waves 34, 36, 38 along the side edges of the metal sheet 26. According to one embodiment, the wave rolling assembly 10 is a die assembly 10 a, for example the assembly 10 a shown in FIG. 4, 5 , or 6. The die assembly 10 a includes a right and left cassette 40, 42 which move vertically to press the metal sheet 26 into a lower lock bead subplate 45 and form the waves 34, 36, 38. The right and left cassette 40, 42 are removable and replaceable in order to accommodate metal sheets 26 of different widths. In the embodiment of FIG. 4 , each cassette 40, 42 includes a locking bead forming pad 44 which moves vertically, independent from the remainder of the cassette 40 or 42, to press the metal sheet 26 into the lower lock bead subplate 45 and form the first wave 32 (lock step). The locking bead forming pad 44 typically applies a pressure to the metal sheet 26 ranging from 40 to 60 metric tons. According to this embodiment, each cassette 40, 42 also includes upper wave roll insert 46 adjacent the locking head forming pad 44 and lower wave roll inserts 46, 48 adjacent the locking bead forming pad 44 for forming the second and third waves 36, 38 therebetween, after the locking bead forming pad 44 forms the first wave 34 (lock step). In the embodiment of FIG. 5 , the locking bead forming pad 44 moves vertically, independent from the remainder of the cassette 40 or 42, to press the metal sheet 26 into the lower wave roll insert 48 and form the first wave 32 (lock step). The upper and lower wave roll inserts 46, 48 then form the second and third waves 36, 38 therebetween. The upper and lower wave roll inserts 46, 48 typically apply a pressure to the metal sheet ranging from 90 to 110 metric tons. The die assembly 10 a is typically used to stretch metal sheets 26 used to form smaller blanks, for example those having a pitch of less than 4000 mm.

According to another example embodiment, the wave rolling assembly 10 includes a roll forming apparatus 10 b. An example of the roll forming apparatus 10 b is shown in FIG. 7 . The roll forming apparatus 10 b includes plurality of rollers 50 which form the first wave 34 (lock step) and additional waves 36, 38 along the edges of the metal sheet 26. The edges run parallel to the direction of travel of the metal sheet 26. The location of the rollers 50 are typically provided in upper and lower rows. The location and size of the rollers can be adjusted depending on the size of the metal sheet 26. The rollers 50 apply a pressure to the metal sheet 26 while the metal sheet 26 travels along the rollers 50. The roll forming apparatus 10 b is typically used to stretch the metal sheets 26 used to form blanks having a pitch of greater than 4000 mm, such as blanks used to form hoods and roofs of vehicles.

After the wave rolling assembly 10, the metal sheet 26 is conveyed to the second leveler 32. The second leveler 32 can have the same design as the first leveler 20, or a different design. The second leveler 32 applies pressure to the metal sheet 26 and flattens the waves 34 36, 38 out of the metal sheet 26 but does not further stretch or thin the material of the metal sheet 26.

Typically, the width of the metal sheet 26 increases by at least 18%, such as 18% to 22%, for example 20%, between the start of the wave rolling assembly 10 and the exit of the second leveler 32. The thickness of the edges of the metal sheet 26 is reduced by forming the waves 34 36, 38 in the metal sheet 26, and the reduction in thickness varies along the waves 34 36, 38. For example, the thickness may not change at the top of peaks and bottom of valleys of the waves 34 36, 38. Typically, the thickness changes are parallel to the direction of the wave 34 36, 38, and the material between the peaks and valleys is gradually thinned. The thinnest areas of the waves 34 36, 38 are typically at center points P between the peaks and valleys, and the thickness decreases gradually from the peaks or valleys to the center points P. Between the start of the wave rolling assembly 10 and the exit of the second leveler 32, the thickness of the edges of the metal sheet 26 is typically reduced by at least 8% to 12% at the center points P. After the step of forming the waves, the edges of the metal sheet 26 are typically spaced from one another by a section of the metal sheet 26 that does not include the waves 34 36, 38.

According to an example embodiment, the initial coil 16 has a width, at the start of the production process, of 1167 mm. The coil 16 is flattened in the first leveler 20 and has a width of 1167 mm upon exiting the first leveler 20. The coil 16 then passes through the wave rolling assembly 10 where the width of the coil 16 increases to 1186 mm. The coil 16 then passes through the second leveler 32, and the metal sheet 26 maintains the width of 1186 mm upon exiting the second leveler 32.

The production process, which includes the wave rolling assembly 10 and the second leveler 32, can be used to manufacture various different components 12 for vehicles. FIG. 8 is an example of a vehicle hood, FIG. 9 is an example of a roof panel, FIG. 10 is an example of a front door panel, and FIG. 11 is another example of a vehicle panel, each manufactured using the wave rolling assembly 10 and the second leveler 32.

It should be appreciated that the foregoing description of the embodiments has been provided for purposes of illustration. In other words, the subject disclosure it is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varies in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of disclosure. 

1. A system for manufacturing a metal component, comprising: a wave forming assembly for forming a plurality of waves in a metal sheet, the wave forming assembly including a plurality of wave roll inserts or rollers spaced from one another for applying pressure to the metal sheet and forming the waves in the metal sheet, a leveler for flattening the waves formed by the wave forming assembly, and a press and die assembly for receiving the metal sheet after the leveler flattens the waves and forming the metal sheet.
 2. The system of claim 1, wherein the leveler is a second leveler, and further including a first leveler for applying pressure to a coil of metal and forming the coil into the metal sheet before the metal sheet enters the wave forming assembly.
 3. The system of claim 2 including a looping pit for receiving the metal sheet from the first leveler before the metal sheet travels to the wave forming assembly. rollers.
 4. The system of claim 1, wherein the leveler includes a plurality of
 5. The system of claim 1, wherein the wave forming assembly is a die assembly including a lower lock bead subplate and a pair of cassettes for receiving the metal sheet therebetween, the cassettes are movable vertically for pressing the metal sheet and forming the waves in the metal sheet, the cassettes are removable and replaceable, each cassette includes a locking bead forming pad movable vertically and independent from the remainder of the cassette for pressing the metal sheet into the lower lock bead subplate and forming a first wave in the metal sheet, each cassette includes an upper wave roll insert adjacent the locking bead forming pad, and each cassette includes a lower wave roll insert adjacent the lower lock bead subplate for forming second and third waves therebetween.
 6. The system of claim 1, wherein the wave forming assembly includes a roll forming apparatus, the roll forming apparatus including a plurality of rollers for forming the waves in the metal sheet.
 7. The system of claim 6 including a plurality of upper rows of the rollers and a plurality of the lower rows of the rollers. sheet,
 8. A wave rolling assembly, comprising: a lower lock bead subplate and a pair of cassettes for receiving a metal sheet therebetween, the pair of cassettes being movable vertically for pressing and forming waves in the metal sheet, the pair of cassettes being removable and replaceable, each cassette including a locking bead forming pad movable vertically and independent from the remainder of the cassette for pressing the metal sheet into the lower lock bead subplate and forming a first wave in the metal sheet, and each cassette including an upper wave roll insert adjacent the locking bead forming pad and a lower wave roll insert adjacent the lower lock bead subplate for forming second and third waves therebetween.
 9. A method of manufacturing a component, comprising the steps of: forming a plurality of waves in a metal sheet, flattening the waves formed in the metal sheet, and forming the metal sheet in a pressure and die assembly after flattening the waves.
 10. The method of claim 9, wherein the steps of forming the waves and flattening the waves stretch the metal sheet in a width direction traverse to a direction of travel of the metal sheet.
 11. The method of claim 10, wherein the width of the metal sheet is increased by 18% to 22% during the steps of forming the waves and/or flattening the waves.
 12. The method of claim 9, wherein the step of forming the waves in the metal sheet includes applying 90 to 110 metric tons to the metal sheet.
 13. The method of claim 9, wherein the step of forming the waves includes forming the waves adjacent opposite edges of the metal sheet, the edges being spaced from one another by a portion of the metal sheet which does not include the waves, and the edges running parallel to a direction of travel of the metal sheet.
 14. The method of claim 9 including flattening a coil of metal to form the coil into the metal sheet before forming the waves in the metal sheet.
 15. The method of claim 9, wherein the step of forming the metal sheet includes forming the metal sheet into the shape of a body panel, door, roof, hood, or other component for a vehicle.
 16. The method of claim 9, wherein the step of forming the waves in the metal sheet is conducted by a wave forming assembly, the wave forming assembly including a plurality of wave roll inserts or rollers spaced from one another for applying pressure to the metal sheet and forming the waves in the metal sheet.
 17. The method of claim 9, wherein the step of forming the waves in the metal sheet is conducted by a wave forming assembly, the wave forming assembly is a die assembly including a lower lock bead subplate and a pair of cassettes for receiving the metal sheet therebetween, the cassettes are movable vertically for pressing the metal sheet and forming the waves in the metal sheet, the cassettes are removable and replaceable, each cassette includes a locking bead forming pad movable vertically and independent from the remainder of the cassette for pressing the metal sheet into the lower lock bead subplate and forming a first wave in the metal sheet, each cassette includes an upper wave roll insert adjacent the locking bead forming pad, and each cassette includes a lower wave roll insert adjacent the lower lock bead subplate for forming second and third waves therebetween.
 18. The method of claim 9, wherein the step of flattening the waves formed in the metal sheet is conducted by a leveler, the leveler is a second leveler, and further including a first leveler for applying pressure to a coil of metal and forming the coil into the metal sheet before the metal sheet enters a wave forming assembly.
 19. The method of claim 18 including a looping pit for receiving the metal sheet from the first leveler before the metal sheet travels to the wave forming assembly.
 20. The method of claim 9, wherein the step of flattening the waves formed in the metal sheet is conducted by a leveler, and the leveler includes a plurality of rollers. 